BioCMPC – Executing an award-winning project
BioCMPC, the two-year project to upgrade the CMPC Guaíba mill line II, is an excellent example of how systematic planning and good cooperation lead to successful project execution. The project was completed within budget and on schedule.
The upgraded and modernized CMPC Guaíba pulp mill line II was started up in November 2023. The project’s execution was a great success – indeed, the targets were achieved slightly faster than planned. According to the CMPC Guaíba mill management, there are several reasons for this award-winning project’s success.
A project of strategic importance
The roughly two-year project upgraded and modernized the CMPC Guaíba mill line II to one of Brazil’s most sustainable pulp mills in waste management, effluent treatment, atmospheric emissions, and gas treatment systems.
Valmet’s team at the Guaíba mill.
“Strategically, this BioCMPC project is extremely important for our company. The project included operational modernization, automation upgrades, and extended environmental management. The environmental improvements provide a more harmonious interaction focused on the quality of life of the community. In addition to the sustainability improvements, the project’s aim was to increase production capacity by 18 percent and the whole mill’s annual production capacity to 2.3 million tonnes,” says Antonio Lacerda, General Director of CMPC Brazil and the Guaíba Unit.
The project was preceded by environmental performance target setting for noise, odor, air emissions, and water consumption, as well as a study to identify production bottlenecks.
A successful project needs good people, good methodology, and good communication.
“The project was divided into 31 initiatives, including nine initiatives for the implementation of new environmental control equipment and the repowering of existing systems, eight initiatives for environmental management, and 14 initiatives for operational modernization. Valmet was our key partner for automation system and process deliveries. Valmet is a reliable partner – we’re confident that their deliveries will be of very high quality and will meet the expected deadlines.”
Plan, coordinate, communicate
The project was executed while the mill was running normally. The upgrades were executed over five shutdowns. Alfredo Castro, BioCMPC Project Director, explains the reasons for the successful project execution.
“It’s a challenge to execute a project at an operating mill, with 4,000 people working on the project’s different phases, and 800 people operating at the mill. We needed to plan all the work so that the upgrades didn’t affect the ongoing production, making smaller and larger changes to all mill islands and the control systems at the same time.”
The mill’s capacity was increased by 18 percent, and the new nominal capacity was reached 113 days after start-up.
“The key to success is plan, plan, and plan again. We made detailed plans for both the macro and micro levels. For example, we had to plan the need for and placement of storage areas, equipment, and cranes carefully, taking into account the site’s very tight physical limits. The planning was done in good cooperation between CMPC, Valmet, and AFRY teams.”
“Another important area is the teams’ expertise. Our teams are experts in running the mill, and Valmet’s team had very good knowledge of EPC project execution. And we shouldn’t forget the role of communication. During the crucial site works, we needed it hour-by-hour between the project and operating teams.”
“All in all, I’d say a successful project needs good people, a good methodology, and good communication,” Castro says.
General view of the CMPC Guaíba mill.
Meeting the project targets
The success can be measured by different metrics.
“Our first goal was the project’s safe implementation, and our achievement was on a very good level. We didn’t have any serious accidents during the project. Similarly, there was no flexibility in environmental and production performance. Despite major transportations and siteworks, we didn’t have any issues with the community,” Castro tells.
“Reaching the new nominal production 113 days after the start-up, not only at peak capacity but as a 30-day average, was a great achievement. Of course, it was very important from the financial perspective to be able to execute the project within budget.”
Global recognition for project management
The project was awarded the PMI Project of the Year 2024 award in the Construction, Infrastructure and Engineering category. Established in 1969, the Project Management Institute (PMI) is the world’s leading not-for-profit membership association for project professionals today, offering a wide range of training and certifications. The PMI award recognizes a complex project that best delivers superior performance in project management practices, superior organizational results, and positive impacts on society.
CMPC Guaiba mill control room.
“It’s an honor to see our efforts recognized on the global stage, demonstrating our ability to execute complex projects with excellence and alignment with the highest global standards. This award is the result of the tireless work of the entire team involved in the BioCMPC project. It demonstrates Brazilian companies’ capability of executing complex projects with the highest management standards,” Lacerda concludes.
Text Lotta Forssell
Valmet’s delivery to the BioCMPC project:
- a new high-power recovery boiler with electrostatic precipitators and an additional baling line, additional evaporation effect, and expansion of ash leaching
- upgrades of wood handling, cooking and fiberline, pulp drying, causticizing, lime kiln, and NCG handling
- upgraded automation system, new advanced process controls, operator training simulator, and extended flow control solutions
